All-solid-state battery electrode alignment via asymmetric segmentation
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Solution Overview
Problem
All-solid-state batteries face challenges in achieving precise alignment during cell assembly, leading to structural instability, misalignment, and potential shorts due to area mismatches between the positive electrode and solid electrolyte layers, which can result in cracks and reduced energy density.
Innovation Solution
The battery design includes a unit cell structure with a positive electrode current collector, a positive electrode active material layer, and a solid electrolyte layer, where the positive electrode active material layer contains first and second sulfide-based solid electrolyte particles of different sizes, and the solid electrolyte layer covers the entire surface of the positive electrode layer, ensuring identical cross-sectional areas and improved alignment, reducing porosity, and enhancing electrical conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the positive electrode layer area is made smaller than the solid electrolyte layer area to prevent short circuits, then safety is improved, but alignment precision deteriorates and structural stability worsens
Solution Approach 1:
The patent applies asymmetry by making the positive electrode layer area intentionally larger than the solid electrolyte layer area, which is the opposite of conventional designs. This asymmetric configuration, combined with a groove structure, allows the electrode to extend beyond the electrolyte boundaries while the groove prevents short circuits, thereby achieving both improved alignment tolerance and maintained safety.
Solution Approach 2:
The patent segments the positive electrode layer into different regions: a first area that contacts the solid electrolyte layer and a second area that extends beyond it. This segmentation allows different portions of the electrode to serve different functions - the first area for electrochemical activity and the second area for alignment reference and structural stability, without causing shorts.
2Reliability
If the positive electrode layer area is made smaller than the solid electrolyte layer area to prevent short circuits, then safety is improved, but structural stability deteriorates due to step differences
Solution Approach 1:
The positive electrode layer is segmented into a first area contacting the solid electrolyte and a second area extending beyond it. This segmentation allows the electrode to maintain continuous structural integrity across the boundary, eliminating step differences that would otherwise cause structural instability during pressing operations.
Solution Approach 2:
The groove is formed in advance in the solid electrolyte layer before electrode assembly. This preliminary action creates a predefined path that guides the electrode layer and prevents it from bridging to the negative electrode, thereby preventing shorts while maintaining structural stability during subsequent pressing operations.
3Reliability
If the positive electrode layer area is made smaller than the solid electrolyte layer area, then short circuit prevention is improved, but manufacturing complexity increases due to misalignment issues
Solution Approach 1:
Instead of making the electrode smaller than the electrolyte layer as in conventional designs, the patent inverts this relationship by making the electrode larger. The groove structure then serves as the limiting feature rather than the electrode boundary, simplifying alignment requirements while maintaining short circuit prevention.
Solution Approach 2:
The groove is formed in advance in the solid electrolyte layer to create a predefined alignment reference. This preliminary action eliminates the need for precise alignment during assembly, as the groove naturally guides the electrode layer into the correct position, thereby reducing manufacturing complexity.
4Quantity of substance
If sulfide-based solid electrolyte particles of different sizes are used in the positive electrode active material layer, then porosity is reduced and energy density is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent uses sulfide-based solid electrolyte particles of different sizes within the same positive electrode active material layer. This local quality variation allows smaller particles to fill pores between larger particles, reducing overall porosity and increasing energy density, while the patent manages the manufacturing precision requirements through appropriate particle size selection and distribution control.
Data Source
Figure 1a~1b
Figure 1c~1d
Figure 2~3a
AI summary
The present disclosure relates to an all-solid-state battery and a method of manufacturing same. More specifically, in an all-solid-state battery according to the present disclosure, structural stability can be improved by ensuring that the shape and area of the cross-section of the positive electrode layer, the solid electrolyte layer, and the negative electrode layer are the same in a unit cell in which the positive electrode layer, the solid electrolyte layer, and the negative electrode layer are stacked, and furthermore, the porosity is reduced by including sulfide-based solid electrolyte particles with different particle sizes inside the positive electrode active material layer, thereby improving the performance of the battery.